JP7054250B2 - Quick custom design methods and systems for smart factories - Google Patents

Description

The present invention relates to the field of industrial automation technology, in particular to rapid custom design methods and systems for smart factories.

With the rapid development of intelligent manufacturing equipment and communication technology, the manufacturing needs for rapid design and rational implementation of automated production lines are increasing day by day.

Custom design adopts technologies and methods such as selection, placement, and transformation based on the design target to form a new design solution with the goal of meeting the differentiated needs of customers.

Factory rapid custom design methods are already an urgent need for intelligent manufacturing.

Factory custom design quickly forms a static factory layout based on the differentiated needs of the customer's production location, expected capacity, process route, legacy equipment, etc., factory equipment operation design and products. It is necessary to complete the motion design of the above and realize the optimization of the upper management system and the integrated design of the factory.

The factory's custom design extends to the integrated integration of equipment, control systems and management software, to the self-adaptive modification of its implementation system and engine and the setting of its implementation efficiency.

Many of the equipment required by factories have different structures and forms, and different controllers and communication interfaces.

However, between the dedicated equipment, the intermediate equipment and the dedicated equipment require collaborative work, and there is frequent communication, which is extremely difficult for the integration of the entire factory line.

The prior art focuses on factory modeling and placement design, is based on modularization, forms placement space, combines technologies such as reasoning and optimization to form design solutions that meet personalization needs, and is offline. Supports simulation and analysis.

These technologies are closer to static design, but their major drawbacks are:

(1) Since the design solution formed by the conventional design method does not consider the factory digitization model and the upper management system in an integrated manner, it realizes an online virtual operation that "issues a production command from the management system to drive the factory digitization model operation". Can not do it. At the same time, command synchronization and information cannot be synchronized between a single digitized model and physical equipment, which prevents the factory virtual operation process from simulating the actual production process and virtual operation of the factory digitized model. The reliability of the analysis results and verification results performed using is not high.

(2) Since the conventional factory custom design process and factory implementation process are seriously separated and the design solution is not evaluated online by the actual implementation process, the design solution is adjusted and optimized based on the actual operation result. It cannot and cannot effectively guarantee the quality of the design.

(3) The design cycle becomes excessively long due to the serialization of the conventional design process, and the factory layout, equipment integration, control system research and development, and management system development are performed in series by the conventional factory custom design process. A major change in will push back the subsequent process directly, resulting in higher change costs and longer cycles.

Overall, current factory custom design technologies lack effective, real-time, integrated verification methods, platforms and optimization technologies.

The prior art has the drawback of lacking effective, real-time, integrated verification methods, platforms and optimization techniques.

The present invention relates to rapid custom design methods and systems for smart factories that are parallelized and fully integrated, with interactively optimized design and implementation processes.

The rapid custom design method of a smart factory according to the present invention is applied to a smart factory design system, and the rapid custom design method of the smart factory includes the following steps A to D.

Step A: Acquire the design request information of the production line, perform modeling with the simulation system based on it, and build the digitized model of the factory and the 3D graphic model of each single machine equipment.

Step B: Complete the operation plan of the single machine equipment, complete in the product distribution and exercise plan, organize the exercise and motion control script, and perform the offline simulation operation until the offline operation becomes normal.

Step C: Using digital twin technology, build a communication channel between the PLC system of the factory digitization model, the factory physical equipment PLC system and the host computer, realize the interconnection of data and information, and down command. The binary synchronization technology of the up information realizes real-time synchronization of physical equipment real-time data, host computer monitoring data and 3D virtual simulation data, and obtains a 3D digital twin model of a smart factory.

Step D: Output the 3D digital twin model of the factory as a blueprint for the design research and development of the single machine equipment, control system, and implementation system that will be continued in the future, and integrate it with the virtual control network and the 3D digital twin model. Synchronize and synchronize online debugging.

Preferably, the method of constructing the factory digitization model in step A includes:

Based on the building structure of the factory, the overall layout of the production line will be carried out by comprehensively considering factors such as the factory distribution format, manufacturing process, production organization format, and equipment geometry format.

If the site shape of the factory space is an elongated area and the material entrances and exits of the factory are located on different sides of the factory, the factory production line is designed in a linear or L-shaped layout.

If the site shape of the factory space shows a square area and the material entrance / exit of the factory is located on the same side of the factory, the factory production line is designed to be U-shaped, and if the material entrance / exit of the factory is located on a different side, S type. Design for layout.

Preferably, the method of constructing the factory digitization model in step A includes:

Based on the selection model of single machine equipment, the balance of the production capacity of the factory is considered first, and the 3D graphic modeling of the transmission link equipment and the cash link equipment included in the dedicated equipment of the single machine equipment is completed, and the 3D virtual design. Complete factory virtual assembly according to the production line layout on the platform.

Preferably, when the 3D graphic modeling of the equipment for a single machine is completed in step A, the equipment that moves and the equipment that does not move are classified and modeled.

Specifically, step C further includes:

Build a virtual control network, use digital twin technology, and build a virtual physical simulation platform, which enables single-machine equipment to achieve operation synchronization with the corresponding single-machine digitization model on the digitization plant. Then, the upper MES system and the factory digital twin model are integrated to realize the operation of the entire line under the generated MES command, and at the same time, the factory digital twin model implementation status is fed back to the MES to realize the online simulation operation.

Specifically, the method of integrating the upper MES system of step C and the factory digital twin model is as follows.

The control network and configuration software build command and information channels for data interaction, and the command down and information up channels enable connection and data synchronization between the factory digital twin model, the host MES system, and the intelligent management system. ..

Preferably, an iterative optimization step is further placed between the step C and the step D.

One order is placed on the MES system by simulation, and the operation result analysis is used to analyze the order production completion date achievement rate, production line balance rate and equipment operation rate, and line robustness, vulnerability, and flexibility of the entire production line. Based on the metric, further tune the smart factory design solution and optimize the metric.

It circulates in this way and adjusts the performance of the repetitive factory.

Specifically, the 3D graphic model of the single machine equipment in step A is a 3D CAD model obtained by using CAD3D design software, and all the moving parts of the single machine equipment of the model are independently displayed and marked. It is possible.

Specifically, the host computer in step C is configuration software.

A smart factory rapid custom design system that applies the smart factory rapid custom design method described above includes a host computer, a simulation system, and a PLC controller.

The simulation system, host computer, and PLC controller construct a communication network of site information and digital commands.

The simulation system acquires design request information of a production line, performs 3D modeling based on it, and constructs a digitized model of a factory and a 3D graphic model of a physical single machine facility.
The simulation system and the physical single machine equipment are connected to the PLC controller at the same time.

The PLC controller includes a synchronous control module, which drives the synchronous operation of the production line simulation model and the physical single machine equipment via data, the production line simulation model and the physical single. Used to collect real-time status data for equipment.

The host computer includes a configuration monitoring system, an ERP system, and a MES management unit.

The configuration monitoring system receives the real-time state data, builds a configuration monitoring view, and performs real-time monitoring of the production line simulation model and a single physical facility.

The MES management unit sends a test command to the PLC controller, receives the real-time state data, analyzes it, generates a physical single machine equipment test result, and converts it into a physical single machine equipment test result. Based on this, we generate a production line optimized design solution.

The smart factory quick custom design method realizes the connection of commands and digital information between the factory digital model and the 3D graphic model of the physical single machine equipment and the host computer by the digital twin method, and the production line Realize design, assembly, debugging, optimization, monitoring and data output.

In the manufacturing process of a production line, in the form of semi-physical simulation, the physical single machine equipment of the unit waiting for the test on the production line is applied to the corresponding production line unit of the production line simulation model, and the semi-simulation Depending on the method, it can be replaced with a realistic production line or partially.

This eliminates the need to wait for the entire production line to be manufactured and assembled for debugging and optimization, allowing each unit to be unit tested and integrated tested during the production line design and manufacturing process. , Production line design solutions can be timely corrected and optimized, shortening debug cycles and reducing input costs.

The host computer analyzes the real-time data of the physical single machine equipment and each sensor in the production line simulation model, performs iterative optimization of the design solution and physical implementation, and performs the production line optimization design solution. , Effectively improve the rationality of production line design, perform production line simulation operation only by semi-physical simulation, and analyze the equipment operation rate, production balance rate, system robustness, etc. of the simulation operation process. It is possible to know the production line design solution with the highest equipment operation efficiency without the need for iterative debugging in a huge real production line, and the production line optimization design solution can be directly ported to the real production system and put into production. Reduce costs, reduce uncertainty between design and production, reduce time to transition from product design to production, increase product reliability and success rate, and ensure system stability It can significantly shorten the product development and production cycle, effectively build the value chain of the whole company, accelerate the introduction of the product to the market, and improve the quality of the product.

It is a flowchart of the rapid custom design method of the smart factory of embodiment of this invention. It is a structural schematic diagram which constructs a communication network of site information and a digital command by a simulation system, a host computer, and a PLC controller of embodiment of this invention. It is an operation principle diagram of the rapid custom design system of the smart factory of embodiment of this invention. It is a comparison schematic diagram of the serialization factory custom design process of the prior art and the parallelization factory custom design process of this invention. It is a schematic diagram of the erection principle of the rapid custom design system of the smart factory of this invention.

(Embodiment)

As shown in FIGS. 1 to 5, the quick custom design method of the smart factory is applied to the smart factory design system, and the quick custom design method of the smart factory includes the following steps A to D.

Step A: Acquire the design request information of the production line, perform modeling with the simulation system based on it, and build the digitized model of the factory and the 3D graphic model of each single machine equipment.

Specifically, it includes the following contents.

Step A1: When constructing the factory digitization model, comprehensively consider factors such as factory distribution format, manufacturing process, production organization format, equipment geometry, etc. based on the building structure of the factory, and the overall layout of the production line. I do.

If the site shape of the factory space is an elongated area and the material entrances and exits of the factory are located on different sides of the factory, the factory production line is designed in a linear or L-shaped layout.

If the site shape of the factory space shows a square area and the material entrance / exit of the factory is located on the same side of the factory, the factory production line is designed to be U-shaped, and if the material entrance / exit of the factory is located on a different side, S type. Design for layout.

Step A2: When constructing the factory digitization model, based on the single machine equipment selection model, first consider the balance of the factory production capacity, complete the 3D graphic modeling of the single machine equipment general equipment, Complete the 3D graphic modeling of the transmission link equipment and cash link equipment included in the dedicated equipment of the single machine equipment, and complete the factory virtual assembly according to the production line layout on the 3D virtual design platform.

When completing the 3D graphic modeling of the equipment for a single machine, the equipment that moves and the equipment that does not move are classified and modeled.

The 3D graphic model of the single machine equipment is a 3D CAD model obtained by using CAD3D design software, and all the moving parts of the single machine equipment in the model can be independently displayed and marked.

Step B: Complete the operation plan of each single machine equipment, complete in the product distribution and motion plan, organize the motion and motion control script, and perform the offline simulation operation until the offline operation becomes normal.

Step C: Using digital twin technology, build a communication channel between the factory digitized model PLC system and the factory physical equipment PLC system and SCADA system, realize the interconnection of data and information, down command and up. The information binary synchronization technology realizes real-time synchronization of physical equipment real-time data, SCADA system monitoring data and 3D virtual simulation data, and obtains a 3D digital twin model of a smart factory.
Specifically, it includes the following contents.

Build a virtual control network, use digital twin technology, and build a virtual physical simulation platform, which enables single-machine equipment to achieve operation synchronization with the corresponding single-machine digitization model on the digitization plant. Then, the upper MES system and the factory digital twin model are integrated to realize the operation of the entire line under the generated MES command, and at the same time, the factory digital twin model implementation status is fed back to the MES to realize the online simulation operation.

When integrating the upper MES system and the factory digital twin model, the control network and the configuration software build the command channel and the information channel, perform data interaction, and the command down channel and the information up channel make the factory digital twin model and the upper MES. It realizes the connection and data synchronization between the system and the intelligent management system.

By repeating the optimization steps, placing a simulation order on one order on the MES system, and analyzing the operation results, the order production completion date achievement rate, production line balance rate and equipment operation rate, and line robustness of the entire production line are vulnerable. Analyze the flexibility and flexibility, further adjust the smart factory design solution based on the analysis index, and optimize the analysis index.

By circulating in this way and repeating the “simulation operation-performance analysis-solution adjustment” optimization process, the factory performance is adjusted.

Step D: Output the factory's 3D digital twin model as a blueprint for design research and development of single equipment, control system, and implementation system that will be continued in the future, and integrate and synchronize with the virtual control network and 3D digital twin model. And synchronize online debugging.

A smart factory rapid custom design system that applies the smart factory rapid custom design method described above includes a host computer, a simulation system, and a PLC controller.

The simulation system, host computer, and PLC controller build a communication network for field information and digital commands.

The simulation system acquires the design request information of the production line, performs 3D modeling based on it, and builds a digitized model of the factory and a 3D graphic model of the physical single machine equipment.

The simulation system and the physical single machine equipment are connected to the PLC controller at the same time.

The PLC controller includes a synchronous control module, which drives the synchronous operation of the production line simulation model and the physical single machine equipment through the data, and the real time of the production line simulation model and the physical single machine equipment. Used to collect state data.

The host computer includes a configuration monitoring system, an ERP system, and a MES management unit.

The configuration monitoring system receives real-time state data, builds a configuration monitoring view, and performs real-time monitoring of the production line simulation model and physical single-machine equipment.

The MES management unit sends test commands to the PLC controller, receives real-time state data, analyzes it, generates physical single-machine equipment test results, and produces based on the physical single-machine equipment test results. Generate a line optimized design solution.

Configuration software is a type of host computer software, and configuration software is a subordinate concept of host computer software and is also called configuration monitoring software system software.

These are in the first-class software platform and development environment of the automated control system monitoring layer, using flexible configuration method, providing users with rapid construction of industrial automated control system monitoring function, general level software tools.

MES (Manufacturing Execution System) is a manufacturing company production process implementation system, and is a production information management system for the manufacturing company factory implementation layer.

MES includes manufacturing data management, planning scheduling management, production adjustment management, inventory management, quality control, human resource management, work center / equipment management, tool tooling management, procurement management, cost management, project board management, production process control, It can be provided to management module companies including basic data integration analysis, upper-level data integration decomposition, etc., and can build a reliable, reliable, comprehensive and feasible manufacturing cooperative management platform.

ERP system is an abbreviation of Enterprise Resource Planning, which collects information technology and advanced management ideas based on information technology, and uses the management idea of systematization as a means of making decisions for corporate employees and planning decision makers. Provides a management platform for.

The digital twin fully utilizes data such as physical models, sensor updates, and operation histories, integrates simulation processes for complex fields, multi-physical quantities, multi-scales, and multiple probabilities, projects them into virtual space, and supports all of the corresponding physical equipment. Also known as "digital mirror" or "digital mapping", reflecting the life cycle process of.

As shown in FIG. 5, the erection principle of the quick custom design system of the smart factory is as follows.

Based on a 3D design platform of a third party, a package for information such as 3D models (assembly standards / structures) of equipment such as dedicated machines, transmission, loading and unloading, storage, moving part motion tracks, sensing equipment and control scripts, communication standards, etc. We will narrow down the parameter model and set up a dedicated library, which will support the rapid custom design of the factory.

Build down command channel and up information channel, depend on mechanism such as software PLC and PLC communication, control network integration, shared data structure and macro target, data bank access component, platform and upper MES system and its engine, lower layer equipment. It supports real-time command communication and field information communication between them, and supports almost physical simulation and semi-physical simulation of the factory.

The smart factory rapid custom design system uses digital twin technology to bridge the PLC and build a communication channel between the factory digitized model software PLC, factory physical equipment PLC, and configuration software, for data and information. Real-time synchronization of equipment real-time data, configuration monitoring data and 3D virtual simulation data is realized by the binary synchronization technology of down command and up information, virtual factory (digitization model), real factory (physical equipment). ) To achieve operation synchronization.

The control network and SCADA system build data interaction between command channel and information channel, and the command down channel and information up channel realize factory digital twin model and upper MES system, intelligent management system connection and data synchronization.

The main beneficial effects of the present invention are as follows.

(1) The design solution can be viewed stereoscopically, and design deviations caused by lack of communication by the language of customers and design personnel or 2D diagrams can be avoided at an early stage, and design modification costs can be significantly reduced.

(2) The quality of the design solution can be quickly evaluated and optimized, and the virtual implementation method is used to perform online analysis and evaluation on the implementation efficiency of the design solution, perform responsive solution adjustment, and repeat the optimization. And the quality of the design can be improved.

(3) The custom design cycle is greatly shortened, and as shown in FIG. 4, the present invention can convert the traditional serialization factory custom design process into a parallelization process. First, it replaces the traditional overall solution design with a factory virtual design process, which forms a factory 3D digital twin model including factory layout, equipment operation, product motion method, etc., and optimizes preliminary design. Complete. Next, various designers will simultaneously research and develop a single machine equipment, control system, and implementation system using the 3D digital twin model of the factory as a blueprint, and integrate and synchronize with the virtual control network and 3D digital twin model. Perform and perform online debugging synchronously, thereby realizing a parallelized research and development process, reducing the number of design products and shortening the design cycle.

(4) Significantly shorten the integration cycle of the entire factory production line, adopt digital twin technology, integrate physical equipment into sections, consolidate previous distribution integration, and avoid control logic and logistics design errors locally. However, the joint test time can be shortened, and the ratio of space occupancy and fund occupancy costs can be reduced.

The embodiments of the present invention described above do not limit the present invention, and therefore, the scope protected by the present invention is based on the scope of claims described later.

Claims (9)

It is a rapid custom design method of a smart factory having a plurality of physical single machine equipment, which is applied to a smart factory design system, and the rapid custom design method of the smart factory includes the following steps A to D. A quick custom design method for smart factories featuring.
Step A: Acquire information on the custom design of the production line, model it with a simulation system, and digitize the single machine and the digitized model of the factory, which are 3D graphic models of each physical single machine equipment. To build.
Step B: Motion planning is performed in the digitized model of the factory, motion planning of the product is performed , motion control script of the product motion and the single machine digitized model is organized, and offline simulation is performed until the offline operation becomes normal. Perform the operation.
Step C: Using the digital twin technology , construct the PLC system of the digitized model of the factory corresponding to the PLC system of the physical single equipment of the factory, and the PLC system of the digitized model of the factory and the factory. A communication channel is constructed between the PLC system of the physical single equipment and the host computer, and the downlink command from the host computer and the uplink information to the host computer are interconnected, and the down command and the uplink are realized. By synchronizing information, real-time synchronization of physical single-machine equipment real-time data and host computer monitoring data and simulation data is realized , and a virtual control network is constructed and virtual using digital twin technology. By constructing each single machine digitization model in the factory digitization model to correspond to each physical single machine equipment of the factory on the physical simulation platform of the factory, each physical single machine equipment The 3D digital twin model of the factory is obtained by realizing the operation synchronization with each single machine digitized model corresponding on the digitized model, and the upper MES (Manufacturing Execution System) system and the 3D digital twin model of the factory are integrated. Then, in the entire production line, the operation under the generated MES command is realized, and at the same time, the implementation status of the 3D digital twin model of the factory is fed back to the MES to realize the online simulation operation.
Step D: The 3D digital twin model of the factory is output for the design research and development of the physical single machine equipment, control system and implementation system to be continued in the future, and the physical single machine designed and researched and developed. The 3D digital twin model of the factory that realized the operation synchronization with the equipment, control system and implementation system and the upper MES system will be integrated , and online debugging will be performed in synchronization. The rapid custom design method for a smart factory according to claim 1, wherein the construction of the method of the digitization model of the factory in the step A includes the following steps.
Steps to comprehensively consider factors such as factory distribution format, manufacturing process, production organization format, equipment geometry, etc., based on the building structure of the factory, and perform the overall layout of the production line,
If the site shape of the factory space presents an elongated area and the material entrances and exits of the factory are located on different sides of the factory, the steps to design the factory production line into a straight or L-shaped layout, and the site shape of the factory space. Steps to design a U-shaped factory production line if the factory material inlet / outlet is located on the same side of the factory, and to design an S-shaped layout if the factory material entrance / exit is located on a different side. .. In step A, building a method for a factory digitization model
Based on the selection model of the single machine equipment, the balance of the production capacity of the factory is considered first, and the 3D graphic modeling of the transmission link equipment and the cash link equipment included in the dedicated equipment of the single machine equipment is completed, and the 3D virtual design. The rapid custom design method for a smart factory according to claim 2, comprising the steps of completing a factory virtual assembly according to a production line layout on the platform. The rapid custom design method for a smart factory according to claim 3, wherein when the 3D graphic modeling of the equipment for a single machine is performed in step A, the equipment that moves and the equipment that does not move are classified and modeled. The method of integrating the upper MES system and the factory 3D digital twin model in step C is described.
The control network and configuration software build down command and up information channels for data interaction, and the down command and up information channels connect and data the factory's 3D digital twin model, host MES system and intelligent management system. The rapid custom design method for a smart factory according to claim 1, characterized in that synchronization is achieved. An iterative optimization step is further set up between step C and step D.
One order is placed on the MES system by simulation, and the operation result analysis is used to analyze the order production completion date achievement rate, production line balance rate and equipment operation rate, and line robustness, vulnerability, and flexibility of the entire production line. The speed of the smart factory according to claim 1, characterized in that the design solution of the smart factory is further adjusted based on the analysis index, the analysis index is optimized, the cycle is performed in this way, and the performance of the repetitive factory is adjusted. Custom design method. The 3D graphic model of the single machine equipment in step A is a 3D CAD model obtained by using CAD3D design software, and all the moving parts of the single machine equipment of the model can be independently displayed and marked. The rapid custom design method for a smart factory according to claim 1. The rapid custom design method for a smart factory according to claim 5, wherein the host computer in step C is configuration software. A smart factory rapid custom design system using the smart factory rapid custom design method according to any one of claims 1 to 8 includes a host computer, a simulation system, and a PLC controller.
The simulation system, host computer and PLC controller build a communication network for site information and digital commands.
The simulation system acquires information on the custom design of the production line, performs 3D modeling based on it, and builds a digitized model of the factory and a single-machine digitized model that is a 3D graphic model of the physical single-machine equipment. death,
The simulation system and the physical single machine equipment are connected to the PLC controller at the same time.
The PLC controller includes a synchronous control module, which drives a simulation model of a production line and a synchronous operation of a physical single machine facility, a simulation model of the production line and a physical unit via data. Used for collecting real-time status data of one equipment,
The host computer includes a configuration monitoring system, an ERP system, and a MES management unit, which receives the real-time state data, builds a configuration monitoring view, and has a simulation model of the production line and a physical single machine. Real-time monitoring of equipment
The MES management unit sends a test command to the PLC controller, receives the real-time state data, analyzes it, generates a physical single machine equipment test result, and uses it as a physical single machine equipment test result. Based on, a smart factory rapid custom design system characterized by producing production line optimized design solutions.

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